Process for treatment of whole-wheat cereals

ABSTRACT

A process for the processing of whole-wheat cereals in which: the grains are subject to a shower wash using only little more water than is necessary to enclose the surface of the grains; counterflowing air is conducted past the grains to remove excess water; and the grains are exposed to a collision turbulence process.

The invention relates to a process for peeling shower-washed whole-wheatcereals by means of diametral collision turbulence friction on anoptimum separation line by localization of a predetermined quantity ofmoisture in a morphologically determined separation area betweenlongitudinal and transverse cell layers. The process is carried out withthe highest efficiency possible in reducing environmentally harmfulsubstances, toxic agents, and problem bacteria by optimizing completelyuniform surface removal and grain crease opening and cleaning withdiametral collision turbulence friction of individual grains, exhaustair discharge of the peeled grain coatings, and centrifugal forceconveyance of the grains. This prepares the cereals for energy savinggrain grinding with a larger surface of the milling product for fasterand higher absorption of water, good expansion, for a larger volume ofdough and baked product, and for an improved gelatinization andefficiency of starch decomposition. From a physiological or foodconsumption point of view, the process achieves kinetic shortening ofthe endosperm cell compounds for efficiency in guiding sour dough andfor a pure taste of the grain, and bread and pastry produced from thegrain, with good digestibility due to hygiene and uncharged microfloraof highly technological refinement with diametral collision turbulencefriction.

The invention also relates to a process for intensive cleaning ofgrains, granulates, pulses, nuts, seeds and other grains with diametralcollision turbulence friction. Preferably the invention involves peelingof shower-washed whole-wheat cereals for a quantitative completion of atechnical process in substantial and material grain tissues and graincomponents due to a less intensive mechanical stress and damage of thegrains by a peeling process and a realization of an optimum separationline by localization of the penetration depth of the water to themorphologically predetermined separation area between longitudinal andtransverse cell layers. This is done by elimination of surfaceconstraint and centering of the water in a shower wash penetratinguniformly fast over the whole hygroscopic surface of the grain.Unabsorbed moisture is centrifuged to avoid allowing it to concentratein the crease, capillaries and deeper coating tissue with deposited dirtparticles. Instead of transcontamination, the reduction of problembacteria, environmentally harmful substances and toxic agents isachieved, and the food-physiological hygienic efficiency of the graincomponents is prioritized.

The diametral collision turbulence friction is realized at a highdifferential speed of 20-50 m/sec between two working profile disks.This achieves a lasting shortening and loosening of the genetic cellcompounds of the grain endosperm for a larger product surface of themilled grains. The results are improved water absorption, swelling,elasticity, volume increase and efficiency in the microflora for thetechnological decomposition of the grain components in the sour dough,and for a pure taste and digestibility from a physiological or foodconsumption point of view, which is clearly perceptible in the millingproduct and in the baked product.

In order to achieve a uniform grain surface removal on the predeterminedseparation line between the longitudinal cell tissue layer to be removedand the transverse cell tissue layer to remain on the grain, grainsprepared according to the invention are collided immediately andrepeatedly in collision turbulence friction, thereby emptying the graincrease, opening it further and emptying it again. This also takes placeafter the coating of each grain has become more elastic and larger dueto the diametral collision friction in the collision turbulence and atthe working surfaces, whereby the coating separates from the grain,falls down and is aspirated with suction air already in a space betweenthe working surfaces arranged diametrally to each other, reroutedhorizontally into the aspiration ring shaft and aspirated axially. Atthe same time, the grains are accelerated over a path of the collisionturbulence friction according to the invention from axial delivery onthe working surface of the rotor with coaxially surrounding parts. Thegrains are accelerated by the working profile form of preferablyrhombus-parallelogram pyramids on the working surfaces at differentangles to an inclined plane at 0 to 180 degrees at an angle of 30 to 60degrees by the high rotational speed of 20-50 m/sec, and the grainsrebound from the axially diametral working surfaces at the same and/or adifferent angle. The grains also collide diametrally turbulently againstother grains, and rub with more and more intensive collision turbulencefriction towards the outer rims of the disks, with the aid of therotational speed that increases with distance from the axis anddifferential rotational speed between the working surfaces, the distancebetween which decreases with distance from the axis. The peeled grainsachieve a lasting shortening and loosening of the cell compounds of theendosperm for an essential energy saving in later, separate milling, andthe milled products can thus absorb more water faster. The resultingdoughs obtain a larger volume with higher elasticity and better swellingof the starch at baking, since more water for starch swelling isavailable.

Amylogram curves of peeled milled product and unpeeled milled product ofthe same lot show a clear volume increase of approximately 40%, anelasticity increase from AE 380 to AE 530 plus elevated Falling Number,an increase of the gelatinization temperature from 69° to 70° C., and asensible higher absorption of water.

The efficiency of the process in reducing environmentally harmfulsubstances, toxic agents like lead, benzpyrene and other harmfulsubstances in the air from industrial plants and a growing number ofrefuse incinerators, and a radioactive charge of e.g. cesium -137 andcesium -134 indicates the food-physiological value of the processaccording to the invention. Its value is demonstrated advantageously bythe reduction of problem bacteria in the biological guiding of sourdough, especially with whole-wheat scraps and flours. About theinfluence of the substrate and the temperature measurement can be said:

Comparing the distribution of yeasts and bacteria in pure sour doughswith the distribution in different spontaneous sour doughs, theconclusion is reasonable that obviously the substrate, i.e. the kind offlour or scrap used and its degree of milling, influences theirproportion more than the temperature at which the spontaneous sourdoughs, and probably also the pure sour doughs, are guided.

If furthermore an advantageous loosening results in better decompositionof the grain components only with pure sour dough guiding, the object ofthe grain surface processing with regard to its food-physiologicalhealth value can be achieved, and is more than just an intensiveprocessing of the grain surface with the known faults of round peeling,the high water consumption and the uncontrolled attack in the hemp, oreven the soaking in limy water (DE-PS 295 27 08).

Also, the germ of the whole-wheat has to be maintained, whereas in drypeeling machines it is removed.

On the other hand, drinking water should be saved and the environmentalcharges by reprocessing be avoided. In this context, the processaccording to the invention allows considerable savings.

Applications with working surfaces upon truncated cones and cylinders,chisels and peeling tools are known that often aim at removal of exactlythe germ (EU-PS 39 30 97, DE-PS 26 33 273, DE-PS 27 16 637 and EP-PS 0327 160).

An essential feature of the present invention is the centrifugation byprofile elevations and/or grooves, e.g. of plane elevations and/orgrooves similar to rhombus-parallelogram pyramids with angles of20°-40°:30°-60° of length : width upon or inside working surfaces,advantageously displaced, which spin coaxially at high rotationaldifferential speed, and on which working surfaces with correspondingdesign are arranged coaxially at high volume distance. The rotationaldifferential speed is 20-60 m/sec without allowing grain breakage, withthe grains on the working path starting at a release angle to aninclined plane at a semicircle up to 180° and an angle depth of 30°-60°,opposite the diametral surface profiles and working surfaces axiallyarranged above, rebound and collide with the grains of others in frontof, above, beside and displaced working surface profiles of 2,000-6,000pieces/m² diametrally in turbulence against each other, rub, and againare displaced by the coaxially surrounding structure elevations and/orgroove by the centrifugal force, and accelerated faster with increase ofthe coaxial distance and conveyed to the outer rim of the ring disks.

Measurements of the impact intensity, the density, the pressure, and theangle of the different forms, number, sizes and angle incidences clearlyshow the efficiency with the same product and same quantity in theimpact density, intensity, impact friction and use of surface.

The working surfaces not touching each other are positioned with theirprofiles diametral to each other and have preferably the form of a key,opposite to the growing centrifugal force generated technically at adistance from the axis that operates with higher dynamics in thecollision turbulence friction for a greater pressing upon the rotor andaccelerator.

The grains and coatings leaving the treatment process at the disk rimare centrifugally bound against a surrounding cylinder around the spacedefined by the aspiration ring shaft, its working surfaces beingequipped with positive and/or negative stampings. The grains falltowards oppositely flowing air in the aspiration ring shaft and into thering collection funnel having an asymmetric spout, the collection funnelbeing perforated by a centripetal cylinder around the shaft, beingaspirated by suction air passing through the cylinder.

In addition, the grains can be conducted centripetally and axially to alower rotor for post-processing and, thereby, experience a secondcollision turbulence friction process.

For the collision turbulence friction, according to the grain size ortype, an adjustable incidence in the axial measure of the diametralworking profiles is necessary to adjust regulatingly the size of thegrain, the genetic grain temper and the optimum collision volume. Thisis achieved by a hollow shaft with a corresponding groove that axiallysupports the rotor processing body with the working surface in a restingposition and movably during operation over the driven full shaft, by acylinder with external threads around the centripetal full shaftreceiving the support of the full shaft, and by a second, largercylinder with internal threads, which receives the support of the hollowshaft with the rotor body, which is axially adjustable by rotation. As aresult, a manual and/or automatic regulating incidence can take placethat projects, depending on the charge, by means of an electroniccomputer, to the through-flow measuring of the shower-wash cone, to anadjustable changed nominal value and delivers automatically andregulatingly, with electronic control.

The double cylinder support is supported upon a plate with a hollowbottom and three feet in a way that, in the case of horizontal turning,the support feet with the double cylinder can be removed and mountedaxially through the bottom plate, in order to change the damaged supportquickly in the case of permanent operation or mass product processing.

Aspiration of the removed coatings takes place during the wholeprocessing phase, in the space between the working surfaces, at thererouting at the collision-brake-rerouting rings at the space around theouter disk rim, and when falling off in an aspiration shaft with airflowing from below in the opposite direction. Aspiration also takesplace through the cylinder penetrating the spout inclination of the ringcollection funnel, axially around the double shaft and the cylindersupports where the removed coatings are aspirated axially, rerouted atthe rotor working body, and discharged upwards into the aspiration ringshaft and at three points through the cover, according to a 3/3 divisionof the telescopic and adjustable rigid working surfaces, including theaspiration ring shaft in a 3/3 division.

In an execution of the machine with one or more post-processing bodies,an aspiration ring shaft each with a reducing ring width is arrangedoutwards and combined above to a ring. So, in the sequence from top tobottom of the axially arranged processing disks, the cross-section ofthe collision turbulence friction disks through the additionalaspiration shaft around the aspiration ring shaft increases, and, alsoin case of preceding supply upon the processing bodies, only oneaspiration ring shaft each conducts the whole-wheat grains to theasymmetric spout of the ring collection funnel.

The efficiency of the collision turbulence friction in maintaining thepeeling of the coating at the predetermined separation line, as well asfor the completeness of peeling, is especially high in case of specialpreparation, if a specific admission with a certain water quantity pertime unit can be assured.

After the necessary quantity of water for the technological treatmentprocess of the admission of the grain surface had been found, thecentrifugation quantity could be reduced to a minimum.

The very narrow tolerance of the specific technological process in thecollection and admission of the grains was resolved technically by thedosage of the delivery quantity upon the tip of a cone adjustable inheight, lastingly distributed axially around the cone tip by a cylinderwith a centripetally incorporated funnel, and by supplying impulses,from a pressure cell or balance under the cone suspension that isautomatically adjustable in elevation, to an electronic computer outsidethat projecting to the changeable nominal value of 3% of the measuredgrain quantity doses the respective quantity of water over an automaticthrough-flow quantity control. Over the spray head underneath the cone,water is admitted centrally upon the grain surface of the centripetallyformed diametrical grain fog, that falls into the spout of thesurrounding funnel and subsequently into the inlet nipple of the axiallyinclined shower-washing centrifuge. Single paddles on a shaft in acylindrical screen with radially surrounding screen slots of 1-1.5×20-39 mm centrifuge loose grain surface water and dissolved dirt into asurrounding tank and conduct it directly from the diametral outletnipple to the collision turbulence friction process.

A pressure cell balance in the suspension of the inlet-regulatingdelivery cone determines the quantity of grain which passed andtransmits the corresponding values to an electronic computer outside theplant that compares the measured values with a nominal value andprojects whether the value is within a maximum tolerance or has to beadjusted. The pressure call balance executes the corresponding orders byitself, if e.g. the penetration depth of the cone tip into the deliverycylinder is given by a signal to the delivery motor, and determines thepredictably necessary change of the path to plus or minus.

In this case, the order is transmitted to a braking motor with a pinioninside the grooved, central, axially vertical round shaft that lowers orraises the shaft supporting the cone, thereby increasing or reducing thepassage quantity.

The pressure cell balance, which is centripetally supported horizontallyon a cross-fitting in the funnel, registers the passage values from thecylinder in which the servo-motor changes the shaft thereby adjustingthe penetration depth.

Pressure rolls on flexible arms hold the cone from inside in verticalbalance from the cylinder upon the electronic pressure cell balance thattransmits the determined data to the computer outside the aggregate,over a cable through one of the empty tubes of the cross-fitting, and inthis way changes the orders to the servo-motor that changes the passageby acceleration and braking.

According to grain type and specific presupposition in the computer, itprojects at intervals of 5-30 sec and adjusts accordingly.

Simultaneously, the water dosage is controlled according to the productindication number over an electronic regulation valve from outside, likealso the diametral distance of the working surfaces over the productindication number and the rotational speed of the mounted drivingvario-motor.

As a total result arise: 1) the greatest efficiency possible inreduction of environmentally harmful substances, toxic agents andproblem bacteria by optimization of the uniform surface removal on apredetermined morphological separation zone and opening of the graincrease with collision cleaning in single grain collision turbulencefriction with centrifugal conveyance and exhaust air discharge ofcoatings and dirt of the shower-washed grain according to the inventionwith uniform admission of the grain surface and localization of thepenetration depth of the water into the longitudinal cell layer andcentrifugation of loose excess water and dissolved surface dirt with atotal use of water of 3%; 2) kinetic shortening efficiency of theendosperm cell compounds in diametral collision turbulence frictionwithout damage of the whole-wheat product and full-worth product andwithout processing and conveying tools with efficiency in the microflorahygiene for the specific biological guiding of the sour dough forefficiency in the decomposition of the grain components, with a puretaste and good digestibility that is also given to the better swellingand the decomposition of the starch since by the peeling and shorteningwith diametral collision turbulence friction, a higher water absorptionof 6-12%, a larger product volume of 40%, faster water absorption of thewhole-wheat of 15-18 times, and higher milling for thefood-physiological maximum value of 8-15% is achieved technologically;3) technically, a new quantity adjustment and water application upon thesingle grain surface in the grain fog formed centripetally diametrally,centrifugally from seven nozzles of water particles centered by a sprayhead, and localization of the penetration depth and diametral collisionturbulence friction through working surface disks with a highdifferential speed of 20-50 m/sec and a large number of working profilesof 2,000-6,000 pieces/m² in rhombus-parallelogram pyramid form, inpositive and/or negative stampings, also on the surrounding collisionbraking ring in the aspiration ring shaft with exhaust air discharge andair aspiration through a cylinder constructed centripetally to the spoutand coaxially around the driving shaft and the double cylinder supports,as well as the grain inlet; and 4) support of the centrifugal conveying(in the diametral collision turbulence friction) at a diametral distanceof the working profile disks that can also be formed like a key, andtechnical consideration of maintenance, repair, product change, spareparts obtaining and costs, as well as the personnel necessary forexecution in the 3/3 drawer access of the working surface profile andcollision braking ring, double cylinder support change, mounting driveunder the bottom and fully automatic electronic regulation of the graindetermination, assignment, water dosage, diametral working profileincidence, rotational speed regulation of the vario-motor, andmonitoring of the water centrifugation.

The process features of the present invention are that the grains aresubject to a shower wash in which only little more water is placed atdisposal than is necessary to cover or enclose the surface of thegrains. Flowing opposite to the water, an airflow is conducted past thegrains, eliminating excess water. The preprocessed grains are exposed tocollision turbulence processes during which they are conducted into achamber with fixed and rotating working surfaces, with the workingsurfaces being provided with projections and/or grooves that diametrallyturbulently accelerate the colliding grains.

The invention is exemplified below by the Figures:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a covered cylinder and a funnel that hangs from thecylinder at an axial distance by means of hanging ties.

FIG. 2 shows a collision turbulence unit according to the presentinvention.

FIG. 3 shows an arrangement provided with screening units, especially asurrounding cylindrical-shaped screen with screen slots and the like.

FIG. 4 shows the arrangement of the units described in FIG. 1 to FIG. 3.

FIG. 5 and 6 show examples for the design of the working surfaces of theworking bodies, in sectional view and top view.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a covered cylinder 2 and a funnel 3 that hangs fromcylinder 2 at an axial distance by means of hanging ties 15.

Upon the cover 19 of the cylinder 2, a funnel 5 is arrangedconcentrically above the tip of concentrical cone 1. The top of the cone1 is adjustable through the distance 8 in an axial direction by anelevation adjustment of a cone suspension 9. Through a control window16, the grain flow inside the cylinder 2 is visible.

The cone 1 ends concentrically at its bottom in a larger funnel 7 thatis suspended underneath the cylinder 2. A tube 4 is led laterally intothe larger funnel 7 to supply water to a spray head 11 with six nozzles17 that are displaced horizontally at 60° increments around the sprayhead and directed towards the funnel 3, which is positionedconcentrically with the funnel 7. The spray head 11 is furthermoreprovided with a central lower nozzle 18 so that a fog forming a hollowcone is sprayed upon the grains completely from the inside.

As shown by the arrow 14, air can reach a suction joint 13 through thehollow cone fog of the grains and through an annular space or a ringslot 10 between the funnel 7 and the cone 1.

The tube 4 is formed by two empty tubes extending towards a tube ring 78resting diametrally upon the walls of the funnel 7. The tube ring 78serves as a support 85 for a passage balance 86. A cylinder 87 effectsupon inner walls of the cone 1 over movable backing roll arms 88 tocontrol the penetration depth of a shaft 90 over a servo-motor 89.

Three support feet 45 and 59 (FIG. 2) that are each dividedlongitudinally by a double flange 58 serve as a support of a verticalshaft 21.

Working bodies 35 and inclined cone surfaces 33 are arranged upon theshaft 21 or a hollow shaft 40 as rotors with working surfaces.

Collision cylinders 38 and 28 are provided to brake and reroute thegrains and to conduct them to a collection funnel 43, opposite tooncoming suction air. The collection funnel is provided with a spout 54.

The outlet slope of the collection funnel 43 is interrupted in the areaof the shaft 21 and the hollow shaft 40 by a cylinder 50 arranged there.A slider 73 conducts the grains around the cylinder 50, through whichthe suction air is aspirated and discharged through an air suction joint24 towards the outside.

With an upper support 42, the shaft 21 is supported upon a machine cover44. Girder sections 29 are provided to absorb dynamic oscillation andbear the weight of the shaft 21. A double cylinder support serves forrerouting the forces to a bottom plate 51 reinforced by a support 39.

Under the bottom plate 51, a geared engine 20/57 for the shaft 21 isarranged.

The preprocessed grains in the funnel 3 (FIG. 1) are conducted to aworking surface of the working body 35 through an inlet 49 (FIG. 2), aninlet funnel 48, and a cylinder 32. The preprocessing is a kind ofshower wash in which the grain surface absorbs moisture and swells up.

In a chamber between a fixed working surface 36 and a working surface ofthe quickly rotating working body 35, considerable turbulence of thegrain flow reaching this chamber occurs. This is not only due to theconsiderable differential speed of the two working surfaces but also,among other factors, to the design of the working surfaces of theworking bodies 35 and 36, the centrifugal forces, and gravity, as wellas to the reciprocal effects of the collisions of single grains. Theworking surface of the working body 35 is formed with a plurality ofaxial projections and/or grooves, preferably in the form of low pyramidsthat virtually "launch" the colliding grains with a distinct axialcomponent of movement, so that their grain crease is opened and acleaning effect achieved. By "pyramid" is meant all possible geometricalforms with an extension tapering off from a bottom area to a tip,including irregular forms that may be distributed nonuniformly upon theworking surfaces.

This processing results in the possibility of removal or peeling of theouter wood fiber coating of the grain, the epidermis with beard, down toa predetermined separation zone, which up to now was not achievable withknown grain cleaning processes. The special advantages of thisprocessing -- the so-called shower wash with subsequent removal of theouter coating by diametral collision turbulence -- results in arelatively large surface for the milling product, lower energyconsumption during milling, and additionally a higher degree of milling.The milling product from grain processed according to the presentinvention can absorb a larger quantity of water and result hence in ahigher volume increase for whole-wheat doughs in which the product isused. Furthermore, the above described pre-processing can avoidenvironmentally harmful substances, toxic agents and problem bacteria,that are often accumulated in large extent upon the epidermis and in thebeard, from getting into the dough, and can facilitate a specificguiding of the sour dough, with the grain components that are importantfor digestibility and consumption from a food-physiological aspect beingdecomposed better.

The above described process of collision turbulence also takes place inthe area between the fixed working surface 34 and the working surface ofthe working body 33, which is also rotated at high speed.

According to the preferred embodiment of the present invention, it ispossible to supply the grains leaving the funnel 3, not directly to theinlet 49, but to an intermediate step in which the surface water iseliminated from the grains. This surface water mostly contains aconsiderable part of the dissolved dirt. Thus, the final product, thegrain to be milled, meets even higher requirements if this surface wateris eliminated before the treatment of the grain by the turbulenceeffect, and dissolved dirt does not move into the grain crease,transcontaminating it.

For the intermediate step, screen units, especially surroundingcylindrical-shaped screens with screen slots and the like, are possible.A unit of this kind is shown in FIG. 3. A steel tank 65 with acollection trough bottom is positioned with a horizontal inclination andthe tank sloping axially upon shorter feet 73 and higher feet 70.Cylinder stubs on a front side of the tank 65 provide an inlet tube 62on the lower front side and, diametrally opposite, an outlet tube 63 onthe higher part.

A drive 68 with a motor 64 rests upon a pipe bridge 80. Loose surfacewater and dissolved dirt are centrifuged through radially surroundingslots of a cylindrical-shaped screen 61 into the tank 65 and can bedischarged at the lowest point through a drain 67.

FIG. 4 shows an arrangement of the already described units, theshower-wash unit according to FIG. 1, the screen unit according to FIG.3, and the collision turbulence unit according to FIG. 2, as well as anelectronic data processing unit that charges the individual unitsaccording to a program and receives the necessary process data.

FIGS. 5 and 6 show examples of the design of the working surfaces of theworking bodies 35 and 36, in sectional view and top view. These are theprismshaped elevations projecting outwards that exercise the abovedescribed effects upon the grains.

I claim:
 1. A process for removing an outer coating of grains ofwhole-wheat cereals, comprising:shower washing the grains to enclose thesurface of the grains with water and removing excess water from thegrains, whereby a predetermined quantity of moisture is absorbed in thegrains in a morphologically determined separation zone betweenlongitudinal and transverse cell layers of the grains; and subjectingthe grains to diametral collision turbulence to remove the outercoatings by conducting the grains into engagement with fixed workingsurface and with rotating working surfaces, the fixed working surfacesand the rotating surfaces defining a chamber, and diametrallyaccelerating the grains turbulently and into diametral collisions withone another through the use of formations on the fixed and rotatingworking surfaces.
 2. The process of claim 1, further comprisingconducting a flow of air past the grains to take away the removed outercoatings.
 3. The process of claim 1, wherein the grains are diametrallyaccelerated by projections and/or grooves on the working surfaces. 4.The process of claim 1, wherein the step of shower washing comprisingshower washing the grains with only slightly more water than isnecessary to enclose the surface of the grains.
 5. The process of claim4, further comprising conducting a flow of air past the grains to takeaway the removed outer coatings.
 6. The process of claim 4, wherein thegrains are diametrally accelerated by projections and/or grooves on theworking surfaces.